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INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR PVG™ Gas - Fired Boiler 9700609 As an ENERGY STAR® Partner, U.S. Boiler Company has determined that the PVG-3, PVG-4, PVG-5, PVG-6 and PVG-7 meet the ENERGY STAR® guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA). For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label. Model Number Heating Contractor Boiler Serial Number Installation Date Phone Number Address 103997-06 - 1/14 Price - $5.00 IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations. The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved the PVG™ Series boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative. The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter. The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. DANGER CAUTION Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage. Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage. WARNING NOTICE Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage. Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards. DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, NO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the gas supplier’s instructions or if the supplier is unavailable, contact the fire department. 2 Special Installation Requirements for Massachusetts A. For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the side wall exhaust vent termination is less than seven (7) feet above grade, the following requirements shall be satisfied: 1. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code in the residential unit served by the side wall horizontally vented gas fueled equipment, a battery operated carbon monoxide detector with an alarm shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. 2. In addition to the above requirements, if there is not one already present, a carbon monoxide detector with an alarm and a battery back-up shall be installed and located in accordance with the installation requirements supplied with the detector on the floor level where the gas equipment is installed. The carbon monoxide detector with an alarm shall comply with 527 CMR, ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment, the installer shall have a period of thirty (30) days to comply with this requirement; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the carbon monoxide detector may be installed on the next adjacent habitable floor level. Such detector may be a battery operated carbon monoxide detector with an alarm and shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. 3. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”. 4. A final inspection by the state or local gas inspector of the side wall horizontally vented equipment shall not be performed until proof is provided that the state or local electrical inspector having jurisdiction has granted a permit for installation of carbon monoxide detectors and alarms as required above. B. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4: 1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and 2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes. C. When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions for installation of the equipment and the venting system shall include: 1. A complete parts list for the venting system design or venting system; and 2. Detailed instructions for the installation of the venting system design or the venting system components. D. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting flue gases, but identifies “special venting systems”, the following shall be satisfied: 1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and 2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions. E. A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation. 3 WARNING This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service. Installation and service must be performed only by an experienced, skilled, and knowledgeable installer or service agency. This boiler must be properly vented. This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air. The interior of the venting system must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions. A clean and unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler’s efficiency. Installation is not complete unless a pressure relief valve is installed into the tapping located on top of appliance. - See the Water Piping and Trim Section of this manual for details. This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative. This boiler contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. Do not touch any components unless they are cool. Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance. Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting up, operating, maintaining or servicing. Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors or liquids. All cover plates, enclosures and guards must be in place at all times. NOTICE This boiler has a limited warranty, a copy of which is included with this boiler. It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete. 4 Table of Contents I.Pre-Installation................................ 7 VIII. System Start-up............................. 35 II. Unpack Boiler................................. 8 IX.Operation...................................... 39 III.Venting............................................ 9 X.Troubleshooting............................ 43 IV. Water Piping and Trim.................. 19 XI.Service........................................... 48 V. Gas Piping..................................... 25 XII. Repair Parts................................... 53 VI.Electrical........................................ 28 Appendix A - Figures..................... 65 VII. Modular Installation..................... 33 Appendix B - Tables....................... 66 Figure 1: Minimum Clearances to Combustibles 5 6 Supply 1¼ NPT Model PVG3 PVG4 PVG5 PVG6 PVG7 PVG8 PVG9 1¼ NPT Return 4 3 Vent ¾ NPT Relief Valve PVG CONNECTION SIZES(DIMENSIONS IN INCHES) Figure 2: Dimensions ‘A’ 11.65 14.72 17.78 20.84 23.90 26.97 30.03 Model PVG3 PVG4 PVG5 PVG6 PVG7 PVG8 PVG9 PVG DIMENSIONAL DATA I. Pre-Installation WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage or personal injury. DANGER Do not install boiler where gasoline or other flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or stored. NOTICE Due to the low water content of the boiler, missizing of the boiler with regard to the heating system load will result in excessive boiler cycling and accelerated component failure. U.S. Boiler DOES NOT warrant failures caused by mis-sized boiler applications. DO NOT oversize the boiler to the system. Modular boiler installations greatly reduce the likelihood of boiler oversizing. A. Installation must conform to the requirements of the authority having jurisdiction. In the absence of such requirements, installation must conform to the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1. Where required by authority having jurisdiction, installation must conform to Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1. B. Appliance is design certified for installation on combustible flooring. Do not install boiler on carpeting. C. Provide clearance between boiler jacket and combustible material in accordance with local fire ordinance. Refer to Figure 1 for minimum listed clearance from combustible material. Recommended service clearance is 24 (610 mm) inches from left side, right side and front. Service clearances may be reduced to minimum clearances to combustible materials. D. Install on level floor. For basement installation provide solid base such as concrete, if floor is not level or if water may be encountered on floor around boiler. Floor must be able to support weight of boiler, water and all additional system components. E. Protect gas ignition system components from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap, control replacement, etc.). F. Provide combustion and ventilation air in accordance with the section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections 8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA-B149.1, or applicable provisions of local building codes. WARNING Adequate combustion and ventilation air must be provided to assure proper combustion. The following guideline is based on the National Fuel Gas Code, ANSI Z223.1/NFPA 54. 1. Determine volume of space (boiler room). Rooms communicating directly with space (through openings not furnished with doors) are considered part of space. Volume [ft³] = Length [ft] x Width [ft] x Height [ft] 2. Determine Total Input of all appliances in space. Round result to nearest 1,000 Btu per hour (Btuh). 3. Determine type of space. Divide Volume by Total Input. a. If result is greater than or equal to 50 ft³ per 1,000 Btuh, space is considered an unconfined space. b. If result is less than 50 ft³ per 1,000 Btuh, space is considered a confined space. 4. Determine building type. A building of unusually tight construction has the following characteristics: a. Walls and ceiling exposed to outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed and sealed, and; b. Weather-stripping has been added on openable windows and doors, and; c. Caulking or sealants applied in joints around window and door frames, between sill plates and floors, between wall-ceiling joints, between wall panels, at plumbing and electrical penetrations, and at other openings. 5. For boiler located in an unconfined space in a building of other than unusually tight construction, adequate combustion and ventilation air is normally provided by fresh air infiltration through cracks around windows and doors. 7 I. Pre-Installation (continued) 6. For boiler located within unconfined space in building of unusually tight construction or within confined space, provide outdoor air through two permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors. Locate one opening within twelve (12) inches of top of space. Locate remaining opening within twelve (12) inches of bottom of space. Minimum dimension of air opening is three (3) inches. Size each opening per following: confined space. Use indoor air if two permanent openings communicate directly with additional space(s) of sufficient volume such that combined volume of all spaces meet criteria for unconfined space. Size each opening for minimum free area of one (1) square inch per 1,000 Btu per hour input of all equipment in spaces, but not less than 100 square inches. 7. Combustion Air/Ventilation Duct Louvers and Grilles. Equip outside openings with louvers to prevent entrance of rain and snow, and screens to prevent entrance of insects and rodents. Louvers and grilles must be fixed in open position or interlocked with equipment to open automatically before burner operation. Screens must not be smaller than ¼ inch mesh. a. Direct communication with outdoors. Minimum free area of one (1) square inch per 4,000 Btu per hour input of all equipment in space. b. Vertical ducts. Minimum free area of one (1) square inch per 4,000 Btu per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area. c. Horizontal ducts. Minimum free area of one (1) square inch per 2,000 Btu per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area. Alternate method for boiler located within Consider the blocking effect of louvers, grilles and screens when calculating the opening size to provide the required free area. If free area of louver or grille is not known, assume wood louvers have 20-25 percent free area and metal louvers and grilles have 60-75 percent free area. CAUTION Avoid operating this boiler in an environment where saw dust, loose insulation fibers, dry wall dust, etc. are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and inspected daily to insure proper operation. II. Unpack Boiler CAUTION WARNING Do not drop boiler. Do not bump boiler jacket against floor. Installation of this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. A. Move boiler to approximate installed position. B. Remove all crate fasteners. C. Lift and remove outside container. Save two of the wooden slats from the container sleeve for use in Steps E and F. D. Remove all boiler hold-down fasteners. E. Tilt the boiler to its front side or back side and slide a wooden slat under the three raised feet. F. Tilt the boiler in the opposite direction and slide another wooden slat under the three raised feet. G. Slide the boiler left or right off the skid using the two wooden slats as runners. H. Move boiler to its permanent location. 8 III. Venting WARNING Do not use this boiler with galvanized, Type 304 or Type 316 stainless steel, non metallic or any other non AL29-4C® based vent systems. Do not use a barometric damper or draft hood with this appliance. Do not use vent dampers with this boiler. Moisture and ice may form on surfaces around termination. To prevent deterioration, surfaces should be in good repair (sealed, painted, etc.). This appliance needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air. Read, understand and follow combustion air instruction restrictions contained in the Pre-Installation instructions of this manual. Do not operate appliance where gasoline or other flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used, stored and/or present in the air. When installing vent pipe through chimney, no other appliance can be vented into the chimney. Do not exceed maximum vent lengths. Refer to Table 4. Failure to install a condensate drain line could cause boiler to shutdown unexpectedly. Table 1: Vent System Options Description Additional Vent Kit Required Installation Drawing and Specification (See Section) 1. Horizontal Power Vent (air from within building) the vent pipe terminates horizontally (through a sidewall). 45° Elbow D. 2. Vertical Power Vent (air from within building) the vent pipe terminates vertically (through the roof). No E. 3. Horizontal Power Vent (air from within building) the vent pipe terminates horizontally (snorkel through a side wall) 45° Elbow F. Option Table 2: Vent System Components Included with Boiler Gasketed Vent System Components Part Number Vent Terminal 3” - Horizontal PVG3 thru PVG6) 8110701 Vent Terminal 3” - Horizontal (PVG7) 8116310 Vent Terminal 4” - Horizontal (PVG8 & PVG9) 8116313 9 III. Venting (continued) A. Vent Guidelines Due to Removal of an Existing Table 3: Vent System Components Vent System Component Part Number 3” Dia. Pipe x 1 Ft 8116296U 4” Dia. Pipe x 1 Ft 100176-01 3” Dia. Pipe x 3 Ft 8116298U 4” Dia. Pipe x 3 Ft 100177-01 Boiler Equivalent Feet of Pipe 1 3 3” Dia. Pipe x 5 Ft 8116300U 4” Dia. Pipe x 5 Ft 100178-01 3” Dia. Pipe x Adjustable 4” Dia. Pipe x Adjustable Equal to Installed Length 100179-01 (1.06 TO 1.64) 3” Dia. 90° Elbow 8116294U 4” Dia. 90° Elbow 100180-01 3” Dia. 45° Elbow 8116292U 4” Dia. 45° Elbow 100181-01 3” Dia. Horizontal Drain Tee 8116302U 5 8116319U 3” Dia. Vertical Drain Tee 8116304U 4” Dia. Vertical Drain Tee 100183-01 3” Single Wall Thimble 8116116 4” Single Wall Thimble 100184-01 3” Double Wall Thimble 103877-01 4” Double Wall Thimble 100185-01 5 2 7½ ----- 4. Place in operation the appliance being inspected. Follow the Lighting (or Operating) Instructions. Adjust thermostat so appliance will operate continuously. 3” Vent Pipe (Equiv. Ft.) 4” Vent Pipe (Equiv. Ft.) Min. Max. Min. Max. 8 50 --- --- --- --- 8 40 PVG3 & PVG4 PVG5 & PVG6 PVG7 PVG8 & PVG9 10 1. Seal any unused openings in the common venting system. 3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers. Table 4: Vent Length Model If an existing boiler is removed When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation: 2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, and other deficiencies which could cause an unsafe condition. 5 4” Dia. Horizontal Drain Tee 100182-01 5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe. 6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning appliance to their previous conditions of use. 7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1 III. Venting (continued) Au moment du retrait d’une chaudière existante, les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d’evacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés au système d’évacuation ne fonctionnent pas: 1. Sceller toutes les ouvertures non utilisées du système d’évacuation. 2. Inspecter de façon visuelle le système d’évacuation pour déterminer la grosseur et l’inclinaison horizontale qui conviennent et s’assurer que le système est exempt d’obstruction, d’étranglement, de fuite, de corrosion et autres défaillances qui pourraient présenter des risques. 3. Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l’espace où les appareils toujours raccordés au système d’évacuation sont installés et les autres espaces du bâtiment. Mettre en marche les sécheuses, tous les appareils non raccordés au système d’évacuation commun et tous les ventilateurs d’extraction comme les hottes de cuisinière et les ventilateurs des salles de bain. S’assurer que ces ventilateurs fonctionnent à la vitesse maximale. Ne pas faire fonctionner les ventilateurs d’été. Fermer les registres des cheminées. 4. Mettre l’appareil inspecté en marche. Suivre les instructions d’allumage. Régler le thermostat de façon que l’appareil fonctionne de façon continue. 5. Faire fonctionner le brûleur principal pendant 5 min ensuite, déterminer si le coupe-tirage déborde à l’ouverture de décharge. Utiliser la flamme d’une allumette ou d’une chandelle ou la fumée d’une cigarette, d’un cigare ou d’une pipe. 6. Une fois qu’il a été déterminé, selon la méthode indiquée ci-dessus, que chaque appareil raccordé au système d’évacuation est mis à l’air libre de façon adéquate. Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale. 7. Tout mauvais fonctionnement du système d’évacuation commun devrait être corrigé de façon que l’installation soit conforme au National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d’installation CAN/CSA-B149.1. Si la grosseur d’une section du système d’évacuation doit être modifiée, le système devrait être modifié pour respecter les valeurs minimales des tableaux pertinents de l’appendice F du National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) des codes d’installation CAN/CSA-B149.1. B. General Guidelines 1. Vent system installation must be in accordance with National Fuel Gas Code, ANSI Z223.1/NFPA 54, Natural Gas and Propane Installation Code, CAN/CSA B149.1 or applicable provisions of local building codes. Contact local building or fire officials about restrictions and installation inspection in your area. 2. This appliance requires a Special Gas Vent. a. The product is designed to use U.S. Boiler supplied AL29-4C® Stainless Steel vent system components. See Table 3 for complete list of U.S. Boiler Vent System Components. b. The following manufacturers offer similar AL294C® components and are approved for use with this product. • Heat-Fab Inc. - Saf-T-Vent (800-772-0739); • Flex-L International Inc. - Star-34 (800-5611980); • Z-Flex U. S., Inc. - Z-Vent (800-654-5600); • Protech Systems, Inc.- FasNSeal™ (800766-3473). The use of these alternate manufacturer’s venting systems will require adapters to connect to the U.S. Boiler supplied vent connector and vent terminal. These adapters are not supplied with this unit and should be obtained from the supplier of the alternate manufacturer’s venting system. c. Once a vent pipe manufacturer and system is chosen never mix and match vent systems. d. Do not use cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone). e. Do not cover non-metallic vent pipe and fittings with thermal insulation. Note: Non-metallic vent cannot be used with this boiler. 3. Install venting system in accordance with these instructions. Refer to the appropriate drawings in this section of this manual to determine the proper configuration of venting system. See Table 1. 4. Position venting system to prevent accumulation of condensate. Slope horizontal portions of vent pipe upwards not less than 1/4 in/ft (21 mm/m) from boiler to vent terminal. les chaudiêres de catégories I doivent présenter des tronçons horizontaux dont la pente montante est d’au moins 1/4 po par pied (21 mm/m) entre la chaudiêre et l’évent. 5. Use noncombustible ¾ inch pipe strap to support horizontal runs and maintain vent location and slope while preventing sags in pipe. Do not restrict thermal expansion or movement of vent system. 11 III. Venting (continued) Maximum support spacing is five (5) feet (1.5 m). Do not penetrate any part of the vent system with fasteners. Soutenez parties horizontales de ventilation pour éviter l’affaisement. Utilisez des colliers de serrage, des crochets on cintres espacées de 5 preds (1.5 m) ou moins. 6. Vent length restrictions are based on equivalent length of vent pipe (total length of straight pipe plus equivalent length of fittings). Maximum vent lengths are listed in Table 4. Do not exceed maximum vent lengths. Table 3 lists equivalent lengths for fittings. Do not include vent terminals in equivalent feet calculations. 7. Provide and maintain vent pipe minimum clearances to combustible materials. Vent pipe minimum clearance to combustible material is four (4) inches (102 mm) when vent is installed in a fully enclosed (chase) application or three (3) inches (76 mm) when vent is installed with at least one side open, similar to a joist bay application. Use double wall thimble [U.S. Boiler Part No. 103877-01 (3”), 100185-01 (4”)] when penetrating a combustible wall. 8. Do not install venting system components on the exterior of the building except as specifically required by these instructions. The vent termination location is restricted as follows: a. Bottom of vent terminal at least twelve (12) inches (300 mm) above grade plus normally expected snow accumulation level. b. Minimum three (3) feet (0.3 m) above any forced air inlet located within ten (10) feet (3 m). c. Minimum four (4) feet (1.2 m) below, four (4) feet (1.2 m) horizontally from, or 1 foot (300 mm) above any door, operable window, or gravity air inlet into any building. d. Minimum clearance from electric meters, gas meters, regulators, and relief equipment. United States. Minimum 4 ft (1.22 m) horizontally from and in no case above or below, unless a 4 ft (1.22 m) horizontal distance is maintained. Canada. Minimum 6 ft (1.83 m) horizontally from and in no case above or below, unless a 6 ft (1.83 m) horizontal distance is maintained. e. Minimum twelve (12) inches from overhang or corner of building. f. Do not terminate over public walkways or over an area where condensate or vapor could create nuisance or hazard or could be detrimental to the operation of regulators, relief valves, or other equipment. 12 g. Minimum 10 feet (2 m) horizontally from an operable opening in an adjacent building. This does not apply to vent terminals 2 feet (0.6 m) or more above or 25 feet (7.6 m) or more below operable openings. 9. Enclose vent passing through occupied or unoccupied spaces above the boiler with material having a fire resistance rating of at least equal to the rating of the adjoining floor or ceiling. Maintain minimum clearances to combustible materials. See Figure 1. Note: For one or two family dwellings, fire resistance rating requirement may not need to be met, but is recommended. 10. Plan venting system to avoid possible contact with plumbing or electrical wires. Start at vent connector on top of boiler and work towards vent terminal. 11. If a non-standard length pipe is required: Gasketed Vent System: The use of the adjustable length pipe (P/N 8116319U) is recommended to complete a non-standard pipe length. This pipe requires a minimum installed length of 12¾ inch and can adjust across a 7 inch gap up to a maximum of 19¾ inch long. (Note for the adjustable pipe the installed length should be measured from the centerline of the bead on the male end of the first pipe to the end of the female pipe excluding the locking band of the second pipe with a single gasket.) Only in the event the adjustable length pipe is not sufficient a standard length pipe may be cut using the procedure outlined below for the GasketLess Vent System. 12.Vent connectors serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure. WARNING Never exceed maximum installed length of 19¾ inches for adjustable length pipe. Risk of flue gas leakage is possible. NOTICE Cut must be square with pipe and filed or sanded smooth before joining. Carefully ensure roundness of cut pipe by hand with gloves before installing. Seal joint with RTV specified in this manual. III. Venting (continued) C. Install Vent Pipe, U.S. Boiler Gasketed Vent System. 1. Procedure for Joining U.S. Boiler Gasketed Vent Pipe and Fittings. See Figure 3. a. Wipe the male end of each joint using an alcohol pad to remove any dirt and grease. b. Align weld seams in pipes and use a slight twisting motion to FULLY insert male end into female end of joint. Ensure bead in male end of pipe is below locking band and rest against the end of the female pipe. Verify the factoryinstalled gasket is not dislodged or cut. c. Tighten locking band by HAND with a 5/16” nut driver until snug plus ¼ turn. DO NOT SECURE JOINTS WITH SHEET METAL SCREWS OR POP RIVETS. DO NOT PUNCTURE THE VENT SYSTEM! d. Once the installation is complete, operate appliance and inspect all joints to ensure that flue gases and/or liquid condensate will not escape. D. Separate Horizontal Venting System. See Figures 4A, 4B and 5. See Figure 28 for Blower Vent Connector Assembly. Vent Piping – 2. Do not exceed maximum vent lengths. Refer to Table 4. 3. Recommended horizontal installation consists of vent being sloped down ¼ inch per foot away from boiler. See Figure 4A. See Figure 4B for an alternate horizontal installation. 4. Use appropriate designed thimbles when passing through combustible walls (thimble use optional for noncombustible walls). Insert thimble through wall from outside. Secure outside flange to wall with nails or screws, and seal ID, OD and vent holes with sealant material. Install inside flange to inside wall, secure with nails or screws, and seal with sealant material. 5. For noncombustible wall application when thimble is not used, size opening such that bell with locking band attached cannot pass through. 6. Join vent terminal to vent pipe. See Figure 5. 7. Insert vent pipe through thimble/opening from outside and join to vent system. Apply sealant between vent pipe and opening/thimble to provide weathertight seal and prevent entry of combustion products into building. 1. This boiler is supplied with components as standard equipment for installation of the separate horizontal venting system. Figure 3: U.S. Boiler Gasketed Vent Joint Detail 13 14 III. Venting (continued) Figure 4: Horizontal – Vent Installation III. Venting (continued) Figure 5: Horizontal – Vent Terminal Configuration (3” or 4” Vent) NOTICE Roof penetrations require the use of roof flashing and storm collar - not supplied with boiler. 3. Slope horizontal runs minimum ¼ inch per foot. Slope towards vertical vent drain tee. Position weld seams in vent pipes, in all horizontal runs, at the top to avoid condensate from lying on the seams. 4. Install fire stops where vent passes through floors, ceilings or framed walls. The fire stop must close the opening between the vent pipe and the structure. 5. Whenever possible, install vent straight through the roof. Refer to Figure 7 if offset is necessary. Maintain minimum clearance to combustible materials. 6. Install Vent Terminal. E. Separate Vertical Venting System - See Figures 6, 7, 8 and 9 Vertical Venting – 1. See Figure 28 for Blower Vent Connector Assembly. Do not exceed maximum vent lengths. Refer to Table 4. 2. Installation of a vertical vent drain tee 8116304U is required on all vertical vent applications. See Figures 6 and 7. Attach vertical vent drain tee directly to elbow or horizontal pipe from an elbow immediately after vent connector. a. Size roof opening to maintain minimum clearance from combustible materials. b. Extend vent pipe to maintain minimum vertical and horizontal distance of twelve (12) inches from roof surface. Allow additional vertical distance for expected snow accumulation. Provide brace as required. Refer to Figure 8. c. Install storm collar on vent pipe immediately above flashing. Apply Dow Corning Silastic 732 RTV Sealant between vent pipe and storm collar to provide weathertight seal. d. Attach vent terminal. 15 16 Figure 6: Vertical Vent Installation III. Venting (continued) Figure 7: Attic Offset 17 Figure 8: Vertical Vent Termination Canada: Extend at least 18 inch (450 mm) above highest point where it passes through roof surface and same distance above any other obstruction within horizontal distance of 18 inches (450 mm). United States: Extend Vent Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve (12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation. III. Venting (continued) III. Venting (continued) F. Optional Exterior Separate Horizontal Vent Terminal Mounting – See Figure 9. 1. See Figure 28 for Blower Vent Connector Assembly. Do not exceed maximum vent lengths. Refer to Table 4. 2. This installation will allow a maximum of seven (7) feet vertical exterior run of the vent piping to be installed . NOTICE Exterior run to be included in equivalent vent lengths. 3. Install vent piping. a. Install vent piping for desired venting system. Refer to specific section for details for vent pipe installation. b. After penetrating wall/thimble, install an AL29-4C® 90° elbow so that elbow leg is in the up direction. c. Install maximum of seven (7) feet of AL29-4C® vent pipe. Refer to Sections C through E for proper procedures for joining vent pipe and fittings. d. Install AL29-4C® 45° elbow to upper AL29-4C® 90° elbow so that leg of 45° is in down direction (see Figure 9). f. Install vent terminal. g. Brace piping if required. Figure 9: Horizontal Vent Terminal Installation [3” Vent (left view) or 4” Vent (right view)] 18 IV. Water Piping and Trim WARNING Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. U.S. Boiler’s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water. A. Design and install boiler and system piping to prevent oxygen contamination of boiler water and frequent water additions. 1. There are many possible causes of oxygen contamination such as: a. Addition of excessive make-up water as a result of system leaks. b. Absorption through open tanks and fittings. c. Oxygen permeable materials in the distribution system. 2. In order to insure long product life, oxygen sources must be eliminated. This can be accomplished by taking the following measures: a. Repairing system leaks to eliminate the need for addition of make-up water. b. Eliminating open tanks from the system. c. Eliminating and/or repairing fittings which allow oxygen absorption. d. Use of non-permeable materials in the distribution system. e. Isolating the boiler from the system water by installing a heat exchanger. f. Use properly designed and operating air elimination devices in water piping. B. Optional Probe LWCO Installation WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer’s instructions. 1. A low water cutoff is required to protect a gas-fired hot water boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e. baseboard on the same floor level as the boiler). In addition, some jurisdictions require the use of a LWCO with a hot water boiler as a redundant safety control. It is recommended that the LWCO control is installed above the boiler to provide the highest level of protection. However, where the LWCO control is approved by the LWCO control manufacturer for installation in a high boiler tapping of a water boiler, the use of the listed LWCO control is permitted when it is installed according to the LWCO manufacturer’s instructions. 2. The recommended location for a LWCO on gas hot water boilers is above the boiler, in the supply piping. The minimum safe water level of a water boiler is at the uppermost top of the boiler; that is, it must be full of water to operate safely. 3. Typically, in residential applications, a probe type LWCO is used instead of a float type, due to their relative costs and the simplicity of piping for a probe LWCO. 4. Piping and fittings required to install LWCO are field supplied. Figure 10: Recommended Probe LWCO Location 19 IV. Water Piping and Trim (continued) 2. The recommended location for an Auxiliary Limit on gas hot water boilers is in the supply piping. See Figure 11 for recommended location. 5. When constructing a piping tree to install LWCO select fittings (tees, elbows etc) and nipples to have the same size (NPT) as boiler supply connection. At minimum, 1-1/4” tee with ¾” branch outlet is required to connect the probe LWCO to the supply piping. See Figure 10. DO NOT REDUCE THE SIZE OF NEAR BOILER SUPPLY FITTINGS AND NIPPLES. 3. Piping and fittings required to install an Auxiliary Limit are field supplied. 4. When constructing a piping tree to install an Auxiliary Limit select fittings (tees, elbows etc) and nipples to have the same size (NPT) as boiler supply connection. At minimum, 1-1/4” tee with 1/2” branch outlet is required to install the limit well into the supply piping. See Figure 11. DO NOT REDUCE THE SIZE OF NEAR BOILER SUPPLY FITTINGS AND NIPPLES. 6. Installation of manual shutoff valve located above the LWCO and the boiler is recommended to allow servicing. Thus LWCO probe can be removed for inspection without draining the heating system. An annual inspection of the probe is recommended. 7. The presence of water covering properly installed LWCO probe will cause the normally open contact of the LWCO to close, thus providing continuity of the 24 VAC service to the boiler gas valve. When water level drops below probe, LWCO contact opens up breaking 24V supply to gas valve and preventing the boiler to fire. 5. When boiler water temperature reaches or exceeds Auxiliary Limit setting, the limit normally closed contact will open, thus interrupting the 24 VAC service to the boiler gas valve. When boiler water temperature drops below limit differential, limit contact closes restoring 24V supply to gas valve and allowing the boiler to fire. 8. 2012 compliant PVG gas hot water boilers have a “plug-in” provision in factory wiring that will accept optional 24VAC probe LWCO harness connector. The optional LWCO kit (P/N 10408301) includes 24VAC probe LWCO, Harness and Instructions addressing piping, wiring and testing after installation. C. Optional Auxiliary Limit Installation 1. Some jurisdictions may require the use of an Auxiliary Limit control with a hot water boiler as a redundant safety control. 20 6. Gas hot water boilers equipped with Intelligent Hydronic Control have a “plug-in” provision in factory wiring that will accept optional 24VAC Auxiliary Limit harness connector. The optional Auxiliary Limit kit (P/N 103696-01) includes 24VAC Auxiliary Limit, Well, Harness and Instructions addressing wiring and testing after installation. D. Connect system supply and return piping to boiler. See Figures 14 and 15. Maintain minimum ½ inch (13 mm) clearance from hot water piping to combustible materials. Figure 11: Recommended Auxiliary Limit Location IV. Water Piping and Trim (continued) NOTICE U.S. Boiler recommends sizing the system circulator to supply sufficient flow (GPM) to allow a 20°F temperature differential in the system. When sizing the system circulator, the pressure drop of all radiators, baseboard and radiant tubing and all connecting piping must be considered. E. Install circulator with flanges, gaskets and bolts provided. Circulator harness allows circulator to be mounted on supply or return. Connect harness to circulator and secure any excess conduit. F. Install supply manifold, pressure/temperature gauge and pressure relief valve. See Figure 12. Pressure Relief Valve must be installed with spindle in vertical position. Installation of the relief valve must comply with the ASME Boiler and Pressure Vessel Code, Section IV. Figure 13: Recommended Piping for Combination Heating & Cooling (Refrigeration) System H. If boiler is used in connection with refrigeration systems, boiler must be installed with chilled medium piped in parallel with the heating boiler using appropriate valves to prevent chilled medium from entering boiler. See Figure 13. I. If boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation, boiler piping must be equipped with flow control valves or other automatic means to prevent gravity circulation of boiler water during the cooling cycle. J. Use a boiler bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperatures may be encountered (i.e. converted gravity circulation system, etc.). Figure 12: Supply Water Manifold Piping WARNING Pressure relief valve discharge piping must be piped such that the potential of severe burns is eliminated. DO NOT pipe in any area where freezing could occur. DO NOT install any shut-off valves, plugs or caps. Consult Local Codes for proper discharge piping arrangement. G. Space heating and domestic water heating with Alliance SL™ water heater. Install Alliance SL™ water heater as a separate heating zone. Refer to Alliance SL™ Installation, Operating and Service Instructions for additional information. Install pipe tee between circulator and boiler return along with second tee in supply piping as shown in Figure 14 or 15. Bypass should be same size as the supply and return lines with valves located in bypass and supply outlet as illustrated in Figure 14 or 15 in order to regulate water flow to maintain higher boiler water temperatures. After the boiler is operational (reference Section VIII. System Start-Up) set by-pass and boiler supply valves to half throttle position to start. Operate boiler until system water temperature reaches normal operating range. Adjust valves to provide 180° to 200°F supply water temperature. Opening the boiler supply valve will raise system temperature, while opening the by-pass valve will lower system supply temperature. K. After the boiler and system have been cleaned and flushed, and before refilling the entire system add appropriate water treatment chemicals, if necessary, to 21 IV. Water Piping and Trim (continued) bring the pH between 7 and 11. To perform a long term pressure test including the boiler, ALL trapped air must first be removed from the boiler. A loss of pressure during such a test, with no visible water leakage, is an indication that the boiler contained trapped air. L. If it is required to perform a long term pressure test of the hydronic system, the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped in the boiler. 22 23 Figure 14: Recommended Boiler Piping For Circulator Zoned Heating Systems IV. Water Piping and Trim (continued) 24 Figure 15: Recommended Water Piping for Zone Valve Zoned Heating Systems IV. Water Piping and Trim (continued) V. Gas Piping 3. Length of piping and number of fittings. Refer to Table 7 for maximum capacity of Schedule 40 pipe. Table 8 lists equivalent pipe length for standard fittings. WARNING Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load. An additional gas pressure regulator may be needed. Consult gas supplier. 4. Corrections for the specific gravity of natural gas can be found in Table 6. Table 6: Specific Gravity Correction Factors for Natural Gas Specific Gravity A. Size gas piping. Design system to provide adequate gas supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Actual point of delivery pressure may be less; contact gas supplier for additional information. Minimum gas valve inlet pressure is stamped on the rating label located in the boiler’s vestibule compartment. 2. Maximum gas demand. Refer to the boiler’s input as printed on its rating label. Also consider existing and expected future gas utilization equipment (i.e. water heater, cooking equipment). Correction Factor Specific Gravity Correction Factor --- --- 0.85 0.81 --- --- 0.90 0.82 0.60 1.00 1.00 0.78 0.65 0.96 1.10 0.74 0.70 0.93 1.20 0.71 0.75 0.90 1.30 0.68 0.80 0.87 1.40 0.66 For materials or conditions other than those listed above, refer to National Fuel Gas Code, ANSI Z223.1 / NFPA54, CAN/CSA B149.1 Natural Gas and Propane Installation Code or size system using standard engineering methods acceptable to authority having jurisdiction. Table 5: Gas Ratings Model Natural /LP Maximum Gas Pressure (in. w.c.) Minimum Natural Gas Pressure (in. w.c.) Inlet to Gas Valve Minimum LP Gas Pressure (in. w.c.) Inlet to Gas Valve Natural Gas Manifold Pressure (in. w.c.) LP Gas Manifold Pressure (in. w.c.) 14 4.5 11.0 3.5 10.0 PVG3 PVG4 PVG5 PVG6 PVG7 PVG8 PVG9 NOTICE PVG boilers built for altitudes greater than 4,999 feet above sea level do not need to be specially orificed for applications up to 10,000 feet. The PVG boiler “H” Model has been certified to operate in atmospheric conditions from 5,000 to 10,000 feet above sea level. Input is naturally derated approximately 2% per every 1000 feet above sea level. The PVG boiler is available in two (2) altitude Models: The “S” Model 0 to 4,999 feet above sea level, and the “H” Model 5,000 to 10,000 feet above sea level. For applications above 10,000 feet, please follow recommendations in current version of NFPA 54. 25 V. Gas Piping (continued) Table 7: Maximum Capacity of Schedule 40 Pipe in CFH* For Natural Gas Pressures of 0.5 psig or Less 0.3 inch w.c. Pressure Drop 0.5 inch w.c. Pressure Drop Length [Feet] ½ ¾ 1 1¼ ½ ¾ 1 1¼ 10 132 278 520 1,050 175 360 680 1,400 20 92 190 350 730 120 250 465 950 30 73 152 285 590 97 200 375 770 40 63 130 245 500 82 170 320 660 50 56 115 215 440 73 151 285 580 60 50 105 195 400 66 138 260 530 70 46 96 180 370 61 125 240 490 80 43 90 170 350 57 118 220 460 90 40 84 160 320 53 110 205 430 100 38 79 150 305 50 103 195 400 * 1 CFH of Natural Gas is approximately equal to 1 MBH. Contact your gas supplier for the actual heating value of your gas. B. Connect boiler gas valve to gas supply system. 4. All above ground gas piping upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as grounding electrode. Refer to National Electrical Code, NFPA 70 or Canadian Electrical Code CSA-C22.1. WARNING Failure to use proper thread compounds on all gas connectors may result in leaks of flammable gas. WARNING Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping. 1. Use methods and materials in accordance with local plumbing codes and requirements of gas supplier. In absence of such requirements, follow National Fuel Gas Code, ANSI Z223.1 /NFPA 54 or CAN/CSA B149.1 Natural Gas and Propane Installation Code. 2. Use thread (joint) compounds (pipe dope) resistant to action of liquefied petroleum gas. 3. Install sediment trap, ground-joint union and manual shut-off valve upstream of boiler gas control valve and outside jacket. See Figure 16. Figure 16: Recommended Gas Piping Table 8: Equivalent Lengths of Standard Pipe Fittings & Valves VALVES FULLY OPEN 26 Pipe Size I.D. Inches Gate Globe Angle Swing Check 90° Elbow 45° Elbow 90° Tee, Flow Through Run 90° Tee, Flow Through Branch ½” 0.622 0.35 18.6 9.3 4.3 1.6 0.78 1.0 3.1 ¾” 0.824 0.44 23.1 11.5 5.3 2.1 0.97 1.4 4.1 1” 1.049 0.56 29.4 14.7 6.8 2.6 1.23 1.8 5.3 1¼” 1.380 0.74 38.6 19.3 8.9 3.5 1.60 2.3 6.9 V. Gas Piping (continued) C. Pressure test. The boiler and its gas connection must be leak tested before placing boiler in operation. 1. Protect boiler gas control valve. For all testing over ½ psig, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig (3.5kPa) or less, isolate boiler from gas supply piping by closing boiler’s individual manual shutoff valve. 2. Locate leaks using approved combustible gas detector, soap and water, or similar nonflammable solution. DANGER Do not use matches, candles, open flames or other ignition source to check for leaks. 27 VI. Electrical DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source. Make sure all power is off before attempting any electrical work. Each boiler must be protected with a properly sized over-current device. Never jump out or make inoperative any safety or operating controls. The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped with a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any controls used with the boiler. Read, understand and follow all wiring instructions supplied with the controls. A. General. Install wiring and electrically ground boiler in accordance with authority having jurisdiction or, in the absence of such requirements, follow the National Electrical Code, ANSI/NFPA 70, and/or the Canadian Electrical Code Part 1, CSA C22.1, Electrical Code. B. A separate electrical circuit must be run from Heat Anticipator in Thermostat should be set to 0.6 amp. If system tends to overheat above the thermostat’s temperature setting, reduce heat anticipator setting by .1 or .2 amps. If system tends to short cycle without reaching desired room temperature, increase heat anticipator setting by .1 or .2 amps. D. For zone valve wiring, a separate 24V transformer the main electrical service with an over-current device/disconnect in the circuit. A service switch is recommended and may be required by some local jurisdictions. Install the service switch in the line voltage “Hot” leg of the power supply. Locate the service switch such that the boiler can be shut-off without exposing personnel to danger in the event of an emergency. Connect the main power supply and ground to the three (3) boiler wires (black, white and green) located in the junction box at the inside top of the boiler jacket. C. Install a room thermostat on an is required rather than attempting to use the boiler mounted control. Consult zone valve manufacturer for assistance. WARNING inside wall about four feet above floor. Never install thermostat on an outside wall or where it will be influenced by drafts, hot or cold water pipes, lighting fixtures, television, rays of the sun or near a fireplace. Keep large furniture away from thermostat so there will be free movement of room air around this control. The combined boiler and circulator amperage must not exceed 15 amps. Install over-current protection in accordance with authority having jurisdiction or, in the absence of such requirements, follow the National Electric Code, NFPA 70, and/or CSA C22.1 Electrical Code. Do not provide over-current protection greater than 15 amperes. E. Refer to Figures 17 and 18 for details on the internal boiler wiring. NOTICE This boiler is equipped with a high water temperature limit rated sensor located inside the internal wiring of the boiler. This limit provides boiler shutdown in the event the boiler water temperature exceeds the set point of the limit control. Certain Local Codes require an additional water temperature limit. In addition, certain types of systems may operate at temperatures below the minimum set point of the limit contained in the boiler. If this occurs, install an additional water temperature limit (Honeywell L4006 Aquastat) located in the system piping as shown in the Water Piping and Trim Section of this manual. Wire as indicated in the Electrical Section of this manual. 28 VI. Electrical (continued) Figure 17: Wiring Connection Diagram 29 VI. Electrical (continued) NOTICE All wire, wire nuts, controls etc. are installer supplied unless otherwise noted. If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below. 30 Figure 18: Wiring Ladder Diagram 31 VI. Electrical (continued) Figure 19: Circulator Zoned System Wiring Diagram 32 VI. Electrical (continued) Figure 20: Zone Valve Zoned System Wiring Schematic VII. Modular Installation A. General Guidelines 1. Read and follow all venting, combustion air, water piping, gas piping and electrical instructions contained in this manual unless otherwise instructed in this section. E. Gas Piping 1. Refer to National Fuel Gas Code, Local Codes and Tables 7 and 8 for gas pipe sizing. Table 9: Modular Boiler Water Manifold Sizing 2. Consult Local Building Codes or National Fuel Gas Code, NFPA 54/ANSI Z222.3 for restrictions and instructions on modular boiler installations. B. Module Sizing U.S. Boiler recommends sizing each boiler in a modular system to provide 20 % of the combined heating load where ever possible. C. Venting 1. Each boiler must have an individual vent pipe. Refer to Venting Section of this manual for venting guidelines and options. Combined Output (MBH) Recommended Minimum Common Water Manifold Size (NPT) < 166 1¼” < 260 1½” < 550 2” < 900 2½” < 2000 3” 2. Each boiler must be piped as shown in Figure 16. WARNING WARNING Do not manifold vent pipes together. If gas pressure in the building is above ½ psig, an additional gas pressure regulator is required. Using one additional regulator for multiple boilers may result in unsafe boiler operation. The additional regulator must be able to properly regulate gas pressure at the input of the smallest boiler. If the regulator cannot do this, two or more additional regulators are required. Consult regulator manufacturer and/or local gas supplier for instructions and equipment ratings. 2. The maximum vent length for each boiler is fifty (50) equivalent feet. 3. The minimum horizontal distance between vent terminations is one (1) foot. Additional horizontal distance is desirable to avoid frost damage to the building. Vent terminations must be at least twelve (12) inches above the ground plus the expected snow accumulation. CAUTION Installing multiple vent terminations close together promotes frost buildup on buildings. To minimize this possibility, extend the distance from the building to the end of the vent termination and increase the horizontal distance between terminations. 4. Multiple vertical vent pipes may be piped through a common conduit or chase so that one roof penetration may be made. Each vent termination must be one (1) foot from other terminations. D. Water Piping (See Table 9 and Figure 21) F. Electrical 1. Each boiler must be provided with a fused disconnect and service switch. 2. Install wiring in accordance with requirements of authority having jurisdiction. In the absence of such requirements, follow the National Electric Code, NFPA 70 and/or CSA C22.1 Electric Code. G. Modular Boiler Control Systems Contact a controls manufacturer such as Honeywell or Tekmar to properly apply a modular control system. Common systems may use outdoor temperature, return water temperature or both to stage the boilers. Installing a low water cutoff in the system piping of modular systems is strongly recommended and may be required by Local Codes. 33 34 Figure 21: Modular Boiler Piping VII. Modular Installation (continued) VIII. System Start-up A. Verify that the venting, water piping, gas piping and 6. Open fill valve (Make-up water line should be located directly after full port ball valve in system supply piping between air scoop and expansion tank). electrical system are installed properly. Refer to installation instructions contained in this manual. B. Confirm all electrical, water and gas supplies are 7. Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds. turned off at the source and that vent is clear of obstructions. 8. Close the opened zone valve or shut-off valve for the zone being purged of air, then open the zone valve or shut-off valve for the next zone to be purged. Repeat this step until all zones have been purged. At completion, open all zone valves or shut-off valves. C. Confirm that all manual shut-off gas valves between the boiler and gas source are closed. WARNING Completely read, understand and follow all instructions in this manual before attempting start up. 9. Close hose bib, continue filling the system until the pressure gauge reads 12 psi. Close fill valve. (Note - If make-up water line is equipped with pressure reducing valve, system will automatically fill to 12 psi. Follow fill valve manufacturer’s instructions). D. Fill entire heating system with water and vent air from system. Use the following procedure on a Series Loop or multi-zoned system installed as per Figure 14 or 15 to remove air from system when filling. 10.Open isolation valve in boiler supply piping. WARNING The maximum operating pressure of this boiler is 30 psig. Never exceed this pressure. Do not plug or change pressure relief valve. 11.Remove hose from hose bib. E. Confirm that the boiler and system have no water leaks. F. Prepare to check operation. 1. Obtain gas heating value (in Btu per cubic foot) from gas supplier. NOTICE 2. Connect manometer to pressure tap on gas valve. Use 1/8 NPT tapping provided. If it is required to perform a long term pressure test of the hydronic system, the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped in the boiler. To perform a long term pressure test including the boiler, ALL trapped air must first be removed from the boiler. A loss of pressure during such a test, with no visible water leakage, is an indication that the boiler contained trapped air. 3. Temporarily turn off all other gas-fired appliances. 4. Turn on gas supply to the boiler gas piping. 5. Confirm that the supply pressure to the gas valve is 14 in. w.c. or less. Refer to Table 5 for minimum supply pressure. 6. Open the field installed manual gas shut-off valve located upstream of the gas valve on the boiler. 7. Using soap solution, or similar non-combustible solution, electronic leak detector or other approved method. Check that boiler gas piping valves, and all other components are leak free. Eliminate any leaks. 1. Close full port ball valve in boiler supply piping. 2. Isolate all zones by closing zone valves or shut-off valves in supply and return of each zone(s). 3. Attach a hose to the vertical hose bib located prior to the full port ball valve in the system supply piping. (Note - Terminate hose in five gallon bucket at a suitable floor drain or outdoor area). DANGER Do not use matches, candles, open flames or other ignition source to check for leaks. 4. Starting with one circuit at a time, open zone valve or shut-off valve in system supply and return piping. 5. Open hose bib. 8. Purge gas line of air. G. Operating Instructions Follow Operating Instructions to place boiler in operation. See Operation Section for details. 35 VIII. System Start-up (continued) Figure 22: Operating Instructions 36 VIII. System Start-up (continued) H. Check pilot burner flame. See Figure 24. Flame 3. Main burners and pilot burner will extinguish and blower will stop when water level drops below low water cutoff probe. Verify limit, thermostat or other controls have not shut off boiler. should be steady, medium hard blue enveloping 3/8 to ½ inch of sensing probe. I. Check main burner flame. See Figure 23. Flame should have clearly defined inner cone with no yellow tipping. Orange-yellow streaks should not be confused with true yellow tipping. 4. Adjust thermostat to lowest setting. Refill boiler. M. Check limit. Jumper Thermostat connections in boiler wiring harness. Allow burners to operate until shutdown by limit. REMOVE JUMPER. N. Adjust gas input rate to boiler. 1. Adjust thermostat to highest setting. 2. Check manifold gas pressure. See Table 5 or rating label located in the boiler’s vestibule compartment. Adjust gas valve pressure regulator as necessary (turn adjustment screw counterclockwise to decrease manifold pressure, or clockwise to increase manifold pressure). If pressure cannot be attained, check gas valve inlet pressure. If less than minimum indicated in Table 5 or boiler’s rating label, contact gas supplier for assistance. Figure 23: 1 Inch Main Burner Flame 3. Clock gas meter for at least 30 seconds. Use Table 10 to determine gas flow rate in Cubic Feet per Hour. Table 10: Gas Flow Rate in Cubic Feet Per Hour Figure 24: Pilot Burner Flame J. Check thermostat operation. Raise and lower temperature setting to start and stop boiler operation. K. Check ignition control module shut-off. Disconnect pilot lead wires from gas valve. If burners do not shutdown, determine cause of malfunction. Replace necessary items and check operation. L. Check low water cutoff (if so equipped). 1. Adjust thermostat to highest setting. Seconds for One Revolution One-Half Cu. Ft. Size of Gas Meter Dial One Cu. Ft. Two Cu. Ft. 30 60 120 240 32 56 113 225 34 53 106 212 36 50 100 200 38 47 95 189 40 45 90 180 42 43 86 172 44 41 82 164 46 39 78 157 48 37 75 150 50 36 72 144 52 35 69 138 54 33 67 133 56 32 64 129 58 31 62 124 60 30 60 120 2. With boiler operating, open drain valve and slowly drain boiler. 37 VIII. System Start-up (continued) WARNING Failure to properly adjust gas input rate will result in over firing or under firing of the appliance. Improper and unsafe boiler operation may result. 4. Determine Input Rate. Multiply gas flow rate by gas heating value. 5. Compare measured input rate to input rate stated on rating plate. a. Boiler must not be over fired. Reduce input rate by decreasing manifold pressure. Do not reduce more than 0.3 inch w.c. If boiler is still overfired, contact your U.S. Boiler distributor or Regional Office for replacement Gas Orifice. b. Increase input rate if less than 98% of rating plate input. Increase manifold gas pressure no more than 0.3 inch w.c. If measured input rate is still less than 98% of rated input: i. Remove Main Burners per procedure in Section XI: Service. ii. Remove gas orifices. Drill one (1) drill size larger (drill size is stamped on orifice, or see Section XII: Repair Parts). iii. Reinstall gas orifices and main burners. Measure input rate. 6. Recheck Main Burner Flame. 7. Return other gas-fired appliances to previous conditions of use. 8. Measure and record air free carbon monoxide (COAF) must be less than 50 ppm. O. Review User’s Information Manual and system operation with owner or operator. 38 IX. operation A. Boiler Sequence of Operation NORMAL OPERATION 1. The PVG Boilers are equipped with an Intelligent Hydronic Control (control). This control replaces the traditional separate ignition control, high limit switch, blower relay and circulator relay and adds energy saving thermal purge features. Energy is saved by starting the circulator and delaying the burner start when there is residual heat available in the boiler. Status STA 1 No call for heat detected Circulator Pre-purge (burner off circulator on) 1 Either condition is true: a. Call for heat detected and boiler temperature higher than operating setpoint. b. Call for heat detected and boiler temperature higher than Start Temperature (140°F default) and Circulator Pre-purge Time has not expired. Self Test 17 Control internal checking Waiting for Pressure Switch to Close (Blower on) 3 The blower is turned on. The control is waiting for the pressure switch to close. Pre-purge 4 The blower is run for a 30 second pre-purge Spark 6 The pilot fuel valve is open and sparking is started. 5. After the thermostat is satisfied the burner, circulator and blower are stopped. Flame Proving 7 The main fuel valve is open and flame is being proven. 6. When a indirect water heater aquastat call for heat is wired to the DHW input the control starts the Domestic Hot Water circulator and, if the boiler temperature is less than the operating setpoint less differential, the blower is energized without delay. Once the pressure switch is proven, the ignition sequence is started allowing gas flow and ignition of the burners. Running 8 The burner runs until the call for heat is satisfied or the operating setpoint is reached. 3.When the thermostat calls for heat the control starts the system circulator and the thermal purge (circulator Pre-purge time) begins. If the time is completed or boiler temperature is less than the Start Temperature (140°F default) the start sequence continues by energizing the blower. Once the pressure switch is proven, the ignition sequence is started allowing gas flow and ignition of the burners. 4. If the thermostat is not satisfied and the operating setpoint is reached the system circulator will continue to operate and the burner will stop. When the boiler water temperature drops below the setpoint less the differential setting the burner will restart. B. Boiler Fault In the event the boiler fails to start, the control provides status information to help determine the cause of the problem. Table 12 provides a list of boiler status codes that are reported. Refer to the Troubleshooting Section for more information. C. Using Display Status Codes displayed in STA Mode Standby (Burner off Circulator off) 2. The boiler’s sequence of operation is shown in Table 11. Table 11: Sequence of Operation The control is located inside the boiler front door. (Figure 25). Figure 25: Intelligent Hydronic Control Description Table 12: Sequence Fault Status Codes displayed in STA Mode Status STA Description Retry / Recycle Delay 10 If the burner fails to light off (no flame signal), it waits 5 minutes and retries or if the control loses flame signal during running, it will wait 10 seconds and then recycle. Pressure Switch Failed to Open 11 The blower is off and the pressure switch as failed to open. Pressure Switch Failed to Close 12 The blower is on and the pressure switch has failed to close. Soft Lockout 13 System is shutdown and will restart following a one hour enforced delay. Hard Lockout 14 System is locked out. A manual or power reset is required to be able to light off again. Limit Open 15 There is a call for heat from the thermostat, but a Safety Limit is open. Flame Present Out of Sequence 16 Flame signal is still present when expected to be 0 (no flame). 39 IX. operation (continued) The STA (status) display code has the below listed values. This list is also available on the control cover. Status Code Displayed in STA Mode Figure 26: Boiler Display The control display, along with Up ñ, Down ò, and “I” keys may be used to view boiler operating status (Figure 26). D. Viewing the Operating Mode Options In operating mode the user may view (but not change) boiler operating status, settings and troubleshooting information. To view control display information: 1. Press and release the “I” key on the control to change from one parameter to the next. Each setting will alternately flash between the relevant display code and its corresponding value. Operating Mode Options StA bt SP HL HdF tt dh FLA rUn CYC Err 40 Status Boiler Temperature Operating Setpoint (Outdoor Reset) High Limit Setting High Limit Differential Heat Request Status DHW Heat Request Status Flame Current Run Time Hours Boiler Cycles Error (see Error Numbers) 1 2 3 4 6 7 8 10 11 12 13 14 15 16 17 Standby Waiting for Pressure Switch to Open Waiting for Pressure Switch to Close Prepurge Spark Flame Proving Running Retry/Recycle Delay Pressure Switch Failed to Open Pressure Switch Failed to Close Soft Lockout Hard Lockout Waiting for Limit to Close Flame Present Out of Sequence Self Test For example, when the “I” key is pressed on the control until “bt” is displayed, it will then flash a three digit number (such as “180”) followed by either “F” (or “C”). This indicates that the boiler water temperature is 180°F. Other operating parameters display the information in a similar fashion. 1 sec Sample Display 1 sec Unit Display OR 1 sec Please note that in operating mode to hold the display on the value the user can press and hold either the Up ñ or Down ò keys and the value will be continuously shown. This may be helpful in watching a value “live”. IX. operation (continued) E. Changing the Adjustable Parameters To adjust parameters such as High Limit Setpoint and High Limit Differential: 1. Access the adjustment mode by pressing and holding the Up , Down , and “I” keys simultaneously for three (3) seconds. This procedure is intended to discourage unauthorized changes or accidental changes to limit settings. 140-180°F Start Temperature On or off Priority time 4. Circulator Pre-purge Time () When the boiler is warm (boiler water temperature higher than 140°F (adjustable using Start Temperature parameter)) and there is a thermostat call for heat, the system circulator is started and boiler firing is delayed Circulator Pre-purge minutes. If the temperature drops below 140°F or there is a DHW call for heat the boiler is started without delay. Additionally, the boiler is started without delay if the thermostat call for heat is initiated when the boiler water temperature is less than 140°F. This feature helps save energy by satisfying home heating needs with residual boiler heat rather than cycling the boiler. The Circulator Pre-purge time has a factory setting of 2 minutes and is field adjustable between 2 and 20 minutes. Refer to Table 13. DH Terminal Function 5. Start Temperature () 2. Press the “I” key to display available Adjustment Mode options. Select an option. Adjustment Mode Options HL_ dF_ Or_ PP_ St_ Pt_ dh_ rst f-C bac panel settings allow water flow to the priority zone after the call for heat ends. The Circulator Overrun Time is adjustable between 0 through 10 minutes. 140-220°F 10-30°F Adjust High Limit Setting Adjust High Limit Differential 0-10 minutes Circulator Overrun Time 2-20 minutes Circulator Pre-purge Time dh or tt2 Reset Lockout F or C Select degrees F or C Mode Back to Operating Mode 3. Press the Up and Down keys to adjust the displayed item to the desired value. 4. To return to the normal operating mode from the Adjustment Mode, when the “bAc” option is displayed, press either the Up ñ or Down ò key. If no keys are pressed, after five (5) minutes the control will automatically return to the Operating Mode. F. More Information about Adjustable Parameters 1. High Limit (HL_) The control is factory programmed with a High Limit Setpoint of 180°F. The burner turns “off” when the boiler water temperature (bt) is above this value. The High Limit setpoint is adjustable between 140° and 220°F. The Operating Setpoint (SP) will equal the High Limit Setpoint. 2. Differential (df_) The control is factory programmed with a Differential of 15°F. The Differential is the number of degrees the boiler temperature must decrease below the Operating Setpoint before the boiler can restart. The differential is adjustable between 10° through 30°F. 3. Circulator Overrun Time (OR_) The control is factory programmed with a Circulator Overrun Time of 0 minutes. Circulator Overrun Time (also called “circulator off delay” or “circulator post purge”) continues circulator operation after a call for heat has ended, sending excess heat from the boiler into the system. Ensure system piping and zone Table 13: Circulator Pre-purge Time example, (PP_ = 2 minutes) Call for Heat Source TT = on TT = on DHW = on DHW = on DHW = on DHW = on DHW Boiler Terminal Temperature Selection tt2 tt2 dh dh <140 >140 <140 >140 <140 >140 Burner Status Start with no delay Start after 2 minute delay Start with no delay Start after 2 minute delay Start with no delay Start with no delay Amount of “Heat available” is calculated by taking the difference between measured boiler water temperature and the Start Temperature setting. Useful “Heat Available” is dependent on the type of heating emitter installed in the home. Heat emitters require a certain minimum temperature to operate effectively. Our default settings reflect cast iron radiators. Fan Coils may require a start temperature setting of 180°F or 160°F before providing heat to the home. The Start Temperature has a factory setting of 140°F and is field adjustable between 140°F and 180°F. 6. Priority Time () When the Priority Time parameter is set to “on” and Domestic Hot Water (DHW) call for heat is “on” the DHW demand will take “Priority” over home heating demand. During Priority Time the system circulator will be forced “off”. Priority Time ends and the system circulator is released to service home heating demand when Domestic Hot Water call for heat is over. When Priority Time parameter is set to “Off” the DHW call for heat does not force “off” the system circulator. The Priority Time has a factory setting of “On” and is field adjustable between “On” and “Off” Refer to Table 14. 41 IX. operation (continued) 7. Domestic Hot Water (DHW) Terminal Function () The control allows configuration of the DHW Circulator output functionality to help the PVG integrate into each installation more effectively. The DHW Circulator output can be connected to a domestic hot water circulator or a second heating zone circulator. These applications are selected as follows: a. When is set equal to Domestic Hot Water Demand (h) When there is an Indirect Water Heater (IWH) the control provides “DHW” input terminals for the IWH Aquastat and “DHW Circulator” output terminals for the DHW Circulator. When there is a DHW call for heat, the System Circulator is “forced off”, the DHW Circulator terminal is energized and the circulator pre-purge time delay control logic is bypassed to allow the boiler to fire without delay. When DHW demand ends the System Circulator “force off” is removed, the circulator can respond normally, and the DHW Circulator is de-energized. The DHW call for heat is detected by a voltage on to the “DHW” terminal. When the Priority Time parameter is set to “off” the System Circulator is not forced off for a DHW call for heat. Refer to Table 14. b. When is set equal to Second Heating Zone () When there is no IWH the “DHW Circulator” output may be configured to control a second heating zone. This is particularly helpful when the home uses only two heating zones. The control replaces the need for a two circulator zone panel. When DHW Terminal Function () is set to “” the control’s two circulator outputs are used to control two independent heating zones. Refer to Table 15. A “TT” input causes a call for heat and energizes the “System Circulator” output to service heating zone 1 and a second zone’s thermostat wired to the “DHW” input causes a call for heat and energizes heating zone 2 circulator wired to the “DHW Circulator” output. When there is a Second Heating Zone (call for heat) the boiler is started and the DHW Circulator terminal is energized. When Second Heating Zone terminal is de-energized the call for heat is ended and the DHW Circulator is deenergized. A Second Heating Zone is detected by sensing a voltage on the DHW terminal. 42 Table 14: DHW Terminal Function () Selection = Domestic Hot Water Demand, (Parameter dh_ = dh) Call for Heat T-T Input Circulator Status Priority Time (Pt_) DHW Input System DHW Circulator Circulator Output Output on off On on off on on On off on off on On off on on off OFF on off on on OFF on on off on OFF off on Table 15: DHW Terminal Function () Selection = Second Heating Zone, (Parameter dh_ = tt2) Call for Heat T-T Input DHW Input Circulator Status System Circulator Output (Zone 1) DHW Circulator Output (Zone 2) off off off off on off on off on on on on off on off on X. troubleshooting check the wiring on the boiler against the wiring diagram in Figures 17 and 18. Ensure that incoming 120 Vac power polarity is correct and that the boiler is properly grounded. Further, ensure that the control power supply is 24 VAC (minimum 18 VAC to maximum 30 VAC) and polarity is correct. A. Before troubleshooting The following pages contain trouble shooting tables for use in diagnosing control problems. When using these tables the following should be kept in mind: 1. This information is only meant to be used by a professional heating technician as an aid in diagnosing boiler problems. 2. Where applicable, perform startup checks and adjustments outlined in Section VIII ‘System Start-Up’. 4. All controls on the boiler are tested at least once in the manufacturing process and a defective control or component is generally the least likely cause. Before replacing a component, try to rule out all other possible causes. 3. In general, these tables assume that there are no loose or miswired electrical connections. Before using these tables inspect all electrical connections on the boiler to make sure that they are tight. Also, 5. When checking voltage across wiring harness pins be careful not to insert the meter probes into the pins. Doing so may damage the pin, resulting in a loose connection when the harness is reconnected. Press “I” key on the control to change from one parameter to the next. Each setting will alternate between display code (for example STA) and value. When (error) is shown: Value Description Possible (status) values: Value Description 2 Pressure Switch Failed to Open 1 Standby 4 Flame current lower than threshold 2 Waiting for Pressure Switch to Open 6 Flame Out of Normal Sequence 3 Waiting for Pressure Switch to Close 18 Electronics Failure 4 Pre-purge 23 Flame Sensed During Pre-purge 6 Spark 29 Pressure Switch Failed to Close 7 Flame Proving 32 Temperature Sensor Failure 8 Running 35 Duplicate Zone Alarm 10 Retry/Recycle Delay 57 Flame Rod Shorted to Ground 11 Pressure Switch Failed to Open 58 AC Line Frequency 12 Pressure Switch Failed to Close 59 Line Voltage Error 13 Soft Lockout 60 Thermostat input higher than threshold 14 Hard Lockout 61 Line Voltage Unstable 15 Waiting for Limit to Close 63 Soft Lockout – Recycles Exceeded 16 Flame Present Out of Sequence 64 Soft Lockout – Internal Failure 17 Self Test 43 X. troubleshooting (continued) Use Control Display (error) Number To Direct TroubleShooting Efforts If the control detects an error it will flash “” (error) followed by a number. Use this number to identify the boiler problem and corrective action in the table below. If there is no Err display proceed to next Section: IQ Boiler Control Error Codes (when "Err" is flashing) Display Status Blank Boiler and Circulator off No 120 Vac power at boiler, check breaker and wiring between breaker panel and boiler. While the blower is “off” the pressure switch failed to open (contact stuck closed). - Check wiring - Kinked or blocked pressure switch tubing - Defective pressure switch Boiler / Control Action(s) Err 2 Pressure Switch Failed to Open Err 4 Flame Current Lower than Threshold Check pilot assembly. Refer to Troubleshooting Section, 6 Err 6 Flame Sensed Out of Normal Sequence Flame sensed out of normal sequence (before opening gas valve or after closing gas valve). Check gas valve operation. Err 18 Electronics Failure 23 Flame Sensed During Pre-Purge Flame sensed during post-purge (before gas valve signaled open). Check the gas valve for proper operation. Replace gas valve is problem persists.. While the blower is “on” the pressure switch failed to close. - Connect manometer to pressure switch. Is differential pressure greater than minimum, replace pressure switch. - Check if tubing is securely connected to canopy - Check if tubing is free of cracks or holes or condensate - Check for blockage in vent/air intake system - Vent system not installed in accordance with installation manual - Wind at horizontal vent terminal in excess of 40 mph - Replace blower Err Cycle power to control. Replace control if problem persists. Err 29 Pressure Switch Failed to Close Err 32 Temperature Sensor Failure Temperature sensor or interface failure (open or short connection, increased connection resistance, dual sensor mismatch) or control hardware failure. Err 35 Duplicate Zone Alarm Refer to IQ Zone Panel Instructions. Err 57 Flame Rod Shorted to Burner Ground Flame Rod shorted to burner ground, this can result from excessive flue gas condensation. - Check for excessive condensate, dry pilot. Adjust setpoint higher. - Check for loose or damaged ignition wire. Err 58 Err 59 Line Voltage Error Err 60 Thermostat Input Higher than Threshold Err 61 Line Voltage Unstable Err 63 Soft Lockout - Maximum Recycles Exceeded Err 64 Soft Lockout - Internal Failure Err 89 Communication Lost 44 AC Line Frequency Error AC Signal is too noisy or frequency is incorrect. Check supply voltage. AC voltage out of specification high or low. Check supply voltage. Check thermostat wiring. Possibly too many heavy loads switching on and off cause erratic supply voltage. Check supply voltage. Maximum number of recycles exceeded. Refer to Troubleshooting Section, 5. The electronics has detected an error. This can be caused by an actual controller internal fault or wiring fault: - Check pilot assembly, - If problem persists, replace the control. Check wiring between control and IQ Zone Panel or IQ Reset Card. X. troubleshooting (continued) Use STA (status) Number To guide TroubleShooting The control will flash “” followed by a number. Use this number to identify the boiler problem in the table below: 1. Boiler and Circulator Off Display / Status Recommended Corrective Action The boiler has not detected a call for heat (tt = off and dh = off). STA1 Standby Burner off Circulator off Check the thermostat: - When a thermostat call for heat is detected control display “” will show “” - Make sure thermostat is calling for heat and contacts (including appropriate zone controls) are closed. Check for loose connection. Check the DHW demand: - When a domestic call for heat is detected “” will show “” - Make sure the DHW aquastat contact is closed. Check for loose connection. 2. Circulator is On, But Boiler is Off Display / Status STA1 Circulator Pre-purge Burner off Circulator on Recommended Corrective Action The boiler is warm and circulator is providing residual boiler heat to building: Check boiler temperature - The boiler will not start until boiler water temperature is less than the Setpoint () minus differential () - If boiler water temperature is higher than Start Temperature (, default = 140 F) and the Circulator Prepurge (, default = 2 minutes) time has not expired, boiler start will be delayed until water temperature drops or time expires. To permit the boiler to start sooner increase Start Temperature parameter. Refer to Operation Section for additional information. 3. Boiler is On, But Circulator is Off Display / Status Recommended Corrective Action Domestic Hot Water (DHW) Priority Forcing Circulator Off StA 8 Burner on Circulator off - When there is a DHW heat request wired to the control’s DHW terminal the System Circulator will be “forced off” for the duration of the DHW heat request. When the DHW heat request ends the System Circulator “force off” is removed, the circulator can respond normally. When the Priority Time, () Parameter is set to “” the System Circulator is not “forced off” for a DHW call for heat. Wiring / Circulator Issue: - Check wiring for loose connection, miswiring - Check circulator 4. Circulator is On, But Blower is Not On Display / Status Recommended Corrective Action Waiting for Limit to Open. STA15 Limit Open - Check Flame Rollout Switch, in the event of excessive blockage of the boiler section flue passageways is developed the flame rollout switch will open interrupting power to control P5-4. The main burners will be extinguished immediately and the circulator will remain on until the thermostat is turned off. If the flame rollout switch is activated, do not attempt to place the boiler in operation. The source of the blockage must be corrected and the identical flame rollout switch replaced by trained and skilled personnel from a qualified service agency. - Check External Limit. 45 X. troubleshooting (continued) 5. Circulator is On, Blower is On but Boiler Fails to Start Display / Status Retry / Recycle Delay StA 11 Pressure Switch Failed to Open STA 12 Pressure Switch Failed to Close Soft Lockout Hard Lockout Flame Out of Sequence 46 Description The Boiler is in “Retry Delay”: - The burner failed to light (no flame signal). After a 5 minute delay, control will attempt to light the burner again. There is no limit to the number of retries. Recycle Delay - The burner loses flame during running mode, “”. After a 10 second delay, control will attempt to light the burner again. If the burner loses flame during running mode, “” during the next six recycles, control will progress to a soft lockout. Refer to Troubleshooting Section, Err 2 for corrective action. Refer to Troubleshooting Section, Err 29 for corrective action. When a soft lockout occurs, boiler will shut down. Boiler automatically restarts once condition that caused the lockout is corrected and the one-hour time delay is completed. Boiler can be restarted sooner than the time delay by entering Adjustment Mode and selecting the reset button (see Adjustment Mode instructions) or by cycling power. Soft Lockout is caused by one of the following: - Err 63, Maximum Recycles Exceeded – The burner lost flame during running mode, “” six times in a row. Refer to recommended corrective actions on next page to help determine the cause of the problem. - , Internal Failure, refer to Error code listing for recommended corrective action. - , Flame sensed during post-purge (before gas valve signaled open). Check the gas valve for proper operation. Replace gas valve is problem persists. When a hard lockout occurs boiler shuts down. If flame is detected in pre-purge control goes to Flame Out of Sequence Before trial, “” and “” is reported. The control gives a flame 10 seconds to disappear. If flame goes away, control resumes heating cycle from the beginning. If it doesn’t “” is cleared and “” is reported. When flame is off control goes to Soft Lockout and “” is cleared. Check gas valve for proper operation. X. troubleshooting (continued) 6. Circulator is On, Blower is On but Boiler Fails to Start (continued) Display / Status Recommended Corrective Action 1. No Spark a. Can you hear sparking while is displayed? - If there is no spark noise replace the control. b. If you can hear spark noise check the following: - Loose connection in ignition cable or ground wire - Continuity of ignition cable - Break in ignition cable insulation - Loose ground connection - Break in pilot ceramic insulator - Incorrect pilot spark gap StA 10 Retry / Recycle Delay StA 13 Soft Lockout 2. No Pilot Flame a. If pilot does not light check the following: - All manual gas valves are open - Supply tubing is not plugged, kinked or leaking - Gas line pressures are good - Gas line is purged of air - Pilot orifice is not plugged (pilot gas is flowing) - Condensate quenching pilot Note: It may be necessary to recycle the “call for heat” more than once to clear the pilot supply tubes of air. b. If no gas flow check the following: - 24 volts across PV and MV/PV at gas valve, if voltage ok replace defective gas valve - Check for break in wiring harness to gas valve - 24 volts across control connector P5–2 and P5–5, if no voltage at control replace defective control 3. Spark does Not Stop When Pilot Lights If the spark does not stop when the pilot lights check the following: - Loose connection in ignition cable or ground wire - Continuity of ignition cable - Clean flame rod - Pilot electrode porcelain cracked - Pilot flame covers flame rod and is steady and blue, if not adjust pilot flame - Low gas pressure at gas valve inlet - Defective control 4. Main Flame Does Not Light If the main burners do not light check the following: - Check orifice size and/or blockage - 24 volts across control terminals P5-8 and P5-5? If no voltage while in defective control. - 24 volts across MV and MV/PV at gas valve? Check for break in wiring harness to gas valve - Defective gas valve 47 XI. Service DANGER This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service. Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify, remove or tamper with any control device. Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health. AVOID Breathing Fiber Particulates and Dust Precautionary Measures: Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear: 1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator 2. Long sleeved, loose fitting clothing 3. Gloves 4. Eye Protection • • • • Take steps to assure adequate ventilation. Wash all exposed body areas gently with soap and water after contact. Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes. Discard used RCF components by sealing in an airtight plastic bag. RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada. First Aid Procedures: • • • • 48 If contact with eyes: Flush with water for at least 15 minutes. Seek immediate medical attention if irritation persists. If contact with skin: Wash affected area gently with soap and water. Seek immediate medical attention if irritation persists. If breathing difficulty develops: Leave the area and move to a location with clean fresh air. Seek immediate medical attention if breathing difficulties persist. Ingestion: Do not induce vomiting. Drink plenty of water. Seek immediate medical attention. XI. Service (continued) WARNING This boiler must only be serviced and repaired by skilled and experienced service technicians. If any controls are replaced, they must be replaced with identical models. Read, understand and follow all the instructions and warnings contained in all the sections of this manual. Never jump out or bypass any safety or operating control or component of this boiler. Read, understand and follow all the instructions and warnings contained in ALL of the component instruction manuals. Assure that all safety and operating controls and components are operating properly before placing the boiler back in service. Keep boiler area free and clear of combustible materials, gasoline and other flammable vapors and liquids. Do not place any obstructions in boiler room that hinder flow of combustion and ventilation air. A.General. Inspection and service should be conducted annually. Turn off electrical power and gas supply while conducting service or maintenance. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 22. CAUTION Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. ATTENTION. Au moment de l’entretien des commandes, étiquetez tous les fils avant de les débrancher. Les erreurs de câblage peuvent nuire au bon fonctionnement et être dangereuses. S’assurer que l’appareil fonctionne adéquatement une fois l’entretien terminé. B. Low water cutoff (if so equipped). Probe Type (Annual Service). Probe type LWCO should be removed once a year, examined and cleaned of any dirt accumulations to assure proper operations. Do not attempt to repair mechanisms in the field. Complete replacement mechanisms, including necessary gaskets and installation instructions, are available from the manufacturer. C. Vent System. Inspect for obstructions, soot accumulation, proper support, and deterioration of pipe, fittings, and joints. 1. Clean terminal screens. Terminals must be free of obstruction, undamaged, with screens securely in place. 2. Terminal and wall thimbles (if used) must be weathertight. Penetration through wall must prevent entry of combustion products into building. 3. Pipe must be full round shape, and show no damage from impact or excessive temperature. 4. Pipe must be supported at minimum five (5) foot (1.5 m) intervals and must not sag. 5. All vent joints must be secure and watertight. 6. All joints must be secure and airtight. Horizontal vent tee drain or vertical vent tee drain (if used) must have minimum 6 inch trap and allow condensate to flow freely. To Clean: a. Disconnect drain tube from drain fitting. b. Flush drain tube with water. Fill trap with water. c. Securely fasten drain tube to drain fitting, providing gas-tight and watertight seal. 7. If pipe must be disassembled for removal of obstructions or resealing of joint, see Section III, Paragraph C. D. Boiler Flue Passages. Inspect for blockage or soot accumulation. 1. Remove Main Burners. See Figure 29. a. Remove front door. b. Disconnect pilot tubing and pilot lead wires at the gas valve. c. Remove wires to Flame Roll-out Switch. d. Remove Burner Access Panel. e. Mark location of Main Burner with Pilot Bracket on gas manifold. f. Hold Main Burner on throat. Lift front of burners to clear orifice. Burner which holds pilot can be removed by lifting the burner adjacent to its right first. 2. Disconnect Vent Connector and Vent Pipe from Blower Outlet. 3. Remove Jacket Top Panel. 4. Disconnect the Black and Gray Silicone Tubing from the Canopy. 49 XI. Service (continued) 5. Disconnect Wiring Harness from Blower Motor. 6. Remove Canopy/Blower Assembly. a. Loosen the (4) screws from Canopy. 7. Remove Flue Gas Baffles. Inspect Flue Gas Baffles for deterioration. 8. Inspect flue passages. Clean with flue brush. See Figure 29. 9. Inspect heating surface in combustion chamber. Clean with straight handle wire brush. 10. Install Flue Gas Baffles. 11. Replace Canopy Assembly and seal. 12. Connect Silicone Tubing between Pressure Fittings on Canopy Assembly and Pressure Switch. Route through bushings in Vestibule Panel . See Figure 27. 13. Install Jacket Top Rear Panel. 14. Connect vent system. See Figure 28. 15. Connect Blower Motor Wiring Harness Figure 28: Blower Vent Connector Assembly 5. Install main burners by reversing procedure to remove burners. a. Pilot burner must be installed in original location. See Table 16. b. Main burners must be properly secured in burner tray slot at rear of firebox and over gas orifice. See Figure 29. c. Pilot gas supply and pilot lead wires must be reconnected. d. Burner access panel must be securely in place. e. Reconnect Flame Roll-out wires. E. Main Burners and Firebox. 1. Vacuum firebox. Exercise care - do not damage base insulation. 2. Clean main burners. Brush top of burners with soft bristle brush. See Figure 29. Vacuum to remove any dirt and lint. 3. Vacuum tip of pilot burner. F. Check operation. Follow steps F through N from 4. Check gas orifices for lint and dirt. Clean as necessary. G. Procedure for measuring differential pressure (See Section VIII: System Start-up. Figure 30). 1. With boiler off, remove Gray and Black Hoses at differential pressure switch. 2. With tees and ¼ inch aluminum stubs, connect water manometer as shown with additional tubing. 3. Start boiler and read Pressure on Manometer when boiler water temperature reaches operating temperature. Refer to Table 17 for minimum readings. Figure 27: Silicone Tubing Assembly 50 NOTE: If switch drops-out before boiler reaches temperature or if pressure differential readings are below minimums shown in Table 17, check for cracks in hose or contact your nearest U.S. Boiler representative. 4. Stop boiler, remove manometer and reconnect hoses to differential pressure switch. See Figures 27 and 30. 51 XI. Service (continued) Figure 29: Flue and Burner Cleanout, 1” Burner XI. Service (continued) Table 16: Pilot Burner Location Model Main Burner with Pilot Bracket Pilot Burner Located Between Main Burners * PVG3 2 2&3 PVG4 3 3&4 PVG5 4 4&5 PVG6 5 5&6 PVG7 6 6&7 PVG8 7 7&8 PVG9 8 8&9 * Main burners numbered left to right as viewed from front of boiler. Figure 30: Differential Pressure Measurement Table 17: Differential Pressure Switch Settings Model Sea Level to 4,999 Ft. (Natural Gas) PVG3 PVG4 PVG5 PVG6 PVG7 .PVG8 PVG9 1.32” w.c. 1.17” w.c. 1.37” w.c. 1.17” w.c. 1.00” w.c. 1.00” w.c. 1.00” w.c. 52 Minimum Differential Pressure Hi Altitude Sea Level to 4,999 Ft. 5,000 Ft. to 10,000 Ft. (LP Gas) (Natural Gas) 0.75” w.c. 0.75” w.c. 0.80” w.c. 0.75” w.c. 0.75” w.c. 0.75” w.c. 0.75” w.c 1.32” w.c. 1.17” w.c. 1.17” w.c. 0.88” w.c. 0.80” w.c. 0.88” w.c. 0.88” w.c. Hi Altitude 5,000 Ft. to 10,000 Ft. (LP Gas) 0.75” w.c. 0.75” w.c. 0.75” w.c. 0.61” w.c. 0.61” w.c. 0.61” w.c. 0.61” w.c XII. Repair Parts All PVG Repair Parts may be obtained through your local U.S. Boiler Wholesale distributor. Should you require assistance in locating a U.S. Boiler distributor in your area, or have questions regarding the availability of U.S. Boiler products or repair parts, please contact U.S. Boiler Customer Service at (717) 481-8400 or Fax (717) 481-8408. 53 XII. Repair Parts (continued) 54 XII. Repair Parts (continued) Key No. Description [Quantity] Part Number PVG3 PVG4 PVG5 PVG6 PVG7 PVG8 PVG9 61707031 61707041 61707051 61707061 61707071 61707081 61707091 [6] 71707003 [6] 71707003 [7] 71707003 1. CASTING ASSEMBLY 1 Section Assembly 1A Left End Section 1B Center Section 1C Right End Section 1D Slip Nipple, #3 [4] 806600009 [6] 806600009 [8] 806600009 [10] 806600009 [12] 806600009 [14] 806600009 [16] 806600009 1E Flue Gas Baffle [2] 71107002 [3] 71107002 [4] 71107002 [5] 71107002 [6] 71107002 [7] 71107002 [8] 71107002 1F Tie Rod, ¼” -20 [2] 100109-01 [2] 100108-05 [2] 100108-07 [2] 100108-13 [2] 100108-14 [2] 100108-15 [2] 100108-16 1G Hex Nut, ¼” -20 71707001 [1] 71707003 [2] 71707003 [3] 71707003 [4] 71707003 71707002 [4] 80860407 55 XII. Repair Parts (continued) 56 XII. Repair Parts (continued) Key No. Description [Quantity] Part Number PVG3 PVG4 PVG5 PVG6 PVG7 PVG8 PVG9 2. BASE ASSEMBLY 2A Base Wrapper 71807031 71807041 71807051 71807061 71807071 71807081 71807091 2B Base Tray 71807032 71807042 71807052 71807062 71807072 71807082 71807092 2C Burner Tray Assembly 61807031 61807041 61807051 61807061 61807071 61807081 61807091 2D Base Front Panel 102705-03 102705-04 102705-05 102705-06 102705-07 102705-08 102705-09 2E Burner Access Panel 102707-03 102707-04 102707-05 102707-06 102707-07 102707-08 102707-09 2F Cerafelt Gasket 1/2” x 2” 6206002 2G Cerafelt Gasket 1/2” x 2” 6206002 2H Base Side Insulation [2] 72007001 2J Base Rear Insulation 72007031 72007041 72007051 72007061 72007071 72007081 72007091 2K Base Front Insulation 72007032 72007042 72007052 72007062 72007072 72007082 72007092 2L Base Leg Assembly 2M Self Tapping Screw, 1/4” -20 x 1/2” 2N Flame Roll-out Switch 80160044 2P Sheet Metal Screw, #8 x 3/4” 80860030 2Q Self Tapping Screw, 10-32 x 3/8” 2R Self Tapping Screw Hex Cap, 5/16 - 18 x 1-1/4” [4] 6186001 [18] 80860700 [5] 80860705 [6] 80860705 [7] 80860705 [4] 80860717 57 XII. Repair Parts (continued) Key No. Description [Quantity] Part Number PVG3 PVG4 PVG5 PVG6 PVG7 PVG8 PVG9 3. BASE ASSEMBLY 3A Burner Cover (Natural Gas Only) 3B Manifold Support Bracket 3C Sheet Metal Screw, #8 x 1/2” [2] 80860000 3D Self Tapping Screw, 10-32 x 3/8” [6] 80860705 58 102033-03 102033-04 102033-05 102033-06 102033-07 102033-08 102033-09 718070001 XII. Repair Parts (continued) Key No. Description [Quantity] Part Number PVG3 PVG4 PVG5 PVG6 PVG7 PVG8 PVG9 Canopy Assembly - Sea Level 61107031 61107041 61107051 61107061 61107071 61107081 61107091 Canopy Assembly - High Altitude 61107032 61107042 61107052 61107062 61107072 61107082 61107092 4. FAN/CANOPY ASSEMBLY 4A 4B Cerafelt 9206005 4C U-Clip [4] 80861512 4D Sheet Metal Screw, #10 x 1” [4] 808600141 4E Fan Gasket 8206085 4F Fan 81161512 4G Lock Washer, #10 [4] 80860636 4H Machine Screw, #10-24 x 2-1/2” [4] 808608982 59 60 XII. Repair Parts (continued) XII. Repair Parts (continued) Key No. Description [Quantity] Part Number PVG3 PVG4 PVG5 PVG6 PVG7 PVG8 PVG9 5. BURNER ASSEMBLY 5A 5B Gas Valve (Natural Gas), Honeywell VR8204P1171 81660282 N/A Gas Valve (Natural Gas), Honeywell VR8304P4496 N/A 81660283 Gas Valve (LP Gas), Honeywell VR8204C3015 81660146 N/A Gas Valve (LP Gas), Honeywell VR8304P4280 N/A 81660181 ½” Gas Manifold 82207031 82207041 82207051 82207061 --- --- --- ¾” Gas Manifold --- --- --- --- 82207071 82207081 82207091 Burner Orifices - Natural Gas #47 [4] 822710 [6] 822710 [8] 822710 [10] 822710 [12] 822710 [14] 822710 [16] 822710 Burner Orifices - LP Gas #56 [4] 822707 [6] 822707 [8] 822707 [10] 822707 [12] 822707 [14] 822707 [16] 822707 5C Pilot Assembly - Natural Gas 103704-01 Pilot Assembly - LP Gas 103705-01 5E Burner w/ Pilot Bracket 100147-01 5F Main Burner [3] [5] [7] [9] [11] [13] [15] 100146-01 100146-01 100146-01 100146-01 100146-01 100146-01 100146-01 5G Pilot Tubing 8236122 5H Self Tapping Screw, ¼ - 20 x ½” 5J Ground Wire Assembly 5D [6] 80860700 103776-01 61 XII. Repair Parts (continued) Key No. Description [Quantity] Part Number PVG3 PVG4 PVG5 PVG6 PVG7 PVG8 PVG9 6. CONTROL PANEL ASSEMBLY 6A Limit Rated Temperature Sensor, 12”, Honeywell 50001464-001 103195-01 6B Transformer, Honeywell AT140B1297 102516-01 6C Boiler Control, Induced Draft, Honeywell S9361A2075 103661-01 6D Control Panel 103727-01 6E Temperature Sensor Clip 102422-01 Differential Pressure Switch Sea Level 0’ - 4,999’ (Natural Gas) 6F Differential Pressure Switch Sea Level 0’ - 4,999’ (LP Gas) Differential Pressure Switch High Altitude 4,999’ - 10,000’ (Natural Gas) Differential Pressure Switch High Altitude 4,999’ - 10,000 (LP Gas) 104576-01 104575-01 80160762 80160761 80160761 104804-01 80160760 80160759 80160959 104804-01 104804-01 104802-01 6G Junction Box 4” x 4” x 1½” 8136259 6H Junction Box Cover 8136180 6J ½” Immersion Well, Honeywell 123869A 80160456 62 104730-01 80160760 XII. Repair Parts (continued) Key No. Description PVG3 PVG4 [Quantity] Part Number PVG5 PVG6 PVG7 PVG8 PVG9 7. JACKET PARTS 7A Left Side Panel 60407002 7B Right Side Panel 60407001 7C Rear Panel 60407033 60407043 60407053 60407063 60407073 60407083 60407093 7D Vestibule Panel 60407034 60407044 60407054 60407064 60407074 60407084 60407094 7E Top Panel 60407032 60407042 60407052 60407062 60407072 60407082 60407092 104148-03 104148-04 104148-05 104148-06 104148-07 104148-08 104148-09 7F Front Door 7G Handle 7H Door Clip [2] 7041921 7J Bushing 8136048 8056184 63 XII. Repair Parts (continued) Key No. Description [Quantity] Part Number PVG3 PVG4 PVG5 PVG6 PVG7 PVG8 PVG9 8. MISCELLANEOUS PARTS CARTON 8A Water Manifold 80607001 8B Temperature/Pressure Gauge 100282-01 8C Circulator Wiring Harness 6130701 8D Safety Relief Valve 81660363 8E Boiler Drain Valve 806603061 8F Vent Terminal 8G Vent Connector 8H Vent Tee AL294C, 3” 8J Vent Tee AL294C, 4” 64 8110701 N/A 8110703 N/A 8110704 8116310 N/A N/A 8116313 Appendix A - Figures Figure Number Page Number Figure 1 5 Minimum Clearances to Combustibles Figure 2 6 Dimensions Description Section III - Venting Figure 3 13 U.S. Boiler Gasketed Vent Joint Detail Figure 4 14 Horizontal - Vent Installation Figure 5 15 Horizontal - Vent Terminal Configuration (3” or 4” Vent) Figure 6 16 Vertical Vent Installation Figure 7 16 Attic Offset Figure 8 17 Vertical Vent Termination Figure 9 18 Horizontal Vent Terminal Installation [3” Vent (left view) or 4” Vent (right view)] Section IV - Water Piping and Trim Figure 10 19 Recommended Probe LWCO Location Figure 11 20 Recommended Auxiliary Limit Location Figure 12 21 Supply Water Manifold Piping Figure 13 21 Recommended Piping for Combination Heating & Cooling (Refrigeration) System Figure 14 23 Recommended Boiler Piping for Circulator Zoned Heating Systems Figure 15 24 Recommended Water Piping for Zone Valve Zoned Heating Systems Section V - Gas Piping Figure 16 26 Recommended Gas Piping Section VI - Electrical Figure 17 29 Wiring Connection Diagram Figure 18 30 Wiring Ladder Diagram Figure 19 31 Circulator Zoned System Wiring Diagram Figure 20 32 Zone Valve Zoned System Wiring Schematic Section VII - Modular Installation Figure 21 34 Modular Boiler Piping Section VIII - System Start-Up Figure 22 36 Operating Instructions Figure 23 37 1 Inch Main Burner Flame Figure 24 37 Pilot Burner Flame Section IX - Operation Figure 25 39 Intelligent Hydronic Control Figure 26 40 Boiler Display Section XI - Service Figure 27 50 Silicone Tubing Assembly Figure 28 50 Blower Vent Connector Assembly Figure 29 51 Flue and Burner Cleanout, 1” Burner Figure 30 52 Differential Pressure Measurement Section XII - Repair Parts N/A Pages 54 thru 64 65 Appendix B - Tables Table Number Page Number Description Section III - Venting Table 1 9 Vent System Options Table 2 9 Vent System Components Included with Boiler Table 3 10 Vent System Components Table 4 10 Vent Length Section V - Gas Piping Table 5 25 Gas Ratings Table 6 25 Specific Gravity Correction Factors for Natural Gas Table 7 26 Maximum Capacity of Schedule 40 Pipe in CFH for Natural Gas Pressures of 0.5 psig or Less Table 8 26 Equivalent Lengths of Standard Pipe Fittings & Valves Section VII - Modular Installation Table 9 33 Modular Boiler Water Manifold Sizing Section VIII - System Start-Up Table 10 37 Gas Flow Rate in Cubic Feet Per Hour Section IX - Operation Table 11 39 Sequence of Operation Table 12 39 Sequence Fault Table 13 41 Circulator Pre-purge Time example, (PP_ = 2 minutes) Table 14 42 DHW Terminal Function (dh_) Selection = Domestic Hot Water Demand, (Parameter dh_ = dh) Table 15 42 DHW Terminal function (dh_) Selection = Second Heating Zone, (Parameter dh_ = tt2) Section XI - Service Table 16 52 Pilot Burner Location Table 17 52 Differential Pressure Switch Settings Section XII - Repair Parts N/A 66 Pages 55 thru 64 SERVICE RECORD DATESERVICE PERFORMED 67 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net 68